2011 Arctic Cat 350, 425, 427 ATV Service Manual

• 2011 model coverage: This 189-page Arctic Cat factory service manual covers the 350 and 425 ATV models. It does not cover a 427. Model-specific material separates the 350 carburetor, CDI, and oil-cooler systems from the 425 EFI, ECU, and liquid-cooling systems.
• Engine and transmission repair: Covers engine removal and installation, top-end service, valve and piston inspection, cam timing, magneto and starter-clutch work, CVT clutch service, crankcase separation, transmission disassembly, countershaft inspection, and final reassembly.
• Fuel, lubrication, and cooling procedures: Includes Keihin CVK34 carburetor and electric-choke service for the 350, throttle-body and electric fuel-pump work for the 425, oil-pump pressure testing, and 425 radiator, thermostat, fan, and water-pump procedures.
• Electrical testing and fault isolation: Provides component-level multimeter and peak-voltage tests for the starting, charging, ignition, switch, sensor, lighting, and drive-selector circuits, plus 425 diagnostic trouble codes and throttle-position-sensor adjustment.
• Drive, brake, suspension, and steering work: Details front-differential and rear-gear-case service, ring-and-pinion setup, axle and CV-boot work, hub service, hydraulic-caliper overhaul and brake bleeding, A-arm and shock replacement, steering-knuckle repair, and toe-out adjustment.
• Factory reference material: Supplies assembly-specific torque tables, clearances, wear limits, fluid data, electrical test specifications, special-tool listings, troubleshooting charts, and annotated service photographs. Electrical coverage is test-focused; the PDF does not contain a separate full-machine wiring schematic.

This manual is suited to experienced technicians and advanced DIY mechanics who are comfortable using precision measuring equipment, electrical meters, pullers, and gear-case setup tools. It is considerably deeper than an owner's or routine-maintenance manual, and valve-guide or valve-seat repair is referred to a qualified machine shop.

Model-Specific Service Coverage

The 350 material follows its carbureted fuel system through electric-choke testing, carburetor removal, disassembly, inspection, float setup, and installation. Its electrical sections cover the CDI unit, oil-temperature and cooling-fan switches, and gear-position switch. The 425 chapters instead address electronic fuel injection, the throttle body, electric fuel pump and level sender, MAP/IAT and engine-coolant-temperature inputs, the ECU, tilt sensor, front-drive selector actuator, and TPS inspection and adjustment. A dedicated DTC table supports fault isolation for EFI and chassis-related malfunctions.

Separate 350 and 425 engine/transmission sequences take the technician from removal through top-side, left-side, right-side, and center-crankcase work. Procedures cover cylinder-head and valve inspection, piston and ring service, cylinder measurement and honing checks, cam-chain timing, magneto/stator components, centrifugal and one-way clutches, drive and driven pulleys, oil-pump inspection, transmission gears and shift components, crankshaft checks, and crankcase reassembly. Top-side and side-cover repairs can be performed with the powertrain in the frame; center-crankcase repair requires engine/transmission removal.

Drivetrain and Chassis Depth

The drive-system section goes beyond axle replacement. It covers front-differential input-shaft and pinion disassembly, ring-gear backlash and end-play setup, tooth-contact inspection, shim selection, seals and bearings, rear drive axles, the rear gear case, hubs, and hydraulic brake calipers. Suspension and frame chapters add front and rear A-arms, shocks, wheels and tires, steering post and tie rods, knuckles, toe-out measurement, racks and body panels, and exhaust-system service. Controls coverage includes the hand-brake master-cylinder assembly, throttle control, and LCD gauge replacement.

Several assemblies are identified as replacement-only rather than rebuildable, including the driven pulley, oil pump, starter, 425 water pump, 425 crankshaft/connecting-rod assembly, shock absorbers, and brake master cylinder. That distinction helps prevent ordering this manual for repair operations the factory publication does not support.

Tools, Visual References, and Repair Cautions

The special-tool tables identify the Crankcase Separator/Crankshaft Remover 0444-152, Magneto Rotor Remover Set 0444-254, Piston Pin Puller 0644-328, Backlash Gauge Tool 0544-010, and Gear Case Seal Installer 0444-224, along with electrical meters, a peak-voltage adapter, and oil-pressure test equipment.

Useful visual references include camshaft and magneto timing-mark views, piston-ring placement illustrations, secondary-gear tooth-contact patterns with a shim-correction chart, front-differential backlash and end-play setup views, the battery-charging chart, and the 425 DTC chart. Connector-location photographs support component testing, but they are not a substitute for a complete wiring diagram.

The manual also calls out assembly errors that can cause expensive damage. Reversing a countershaft gear or sliding dog can damage the transmission, while removing a staked pinion lock collar before the staking is fully cleared can destroy the gear-case housing threads. Fuel-system work must be performed away from ignition sources, the ATV must be securely supported for chassis service, and used brake fluid must not be reused.